Can't seem to get lower leg back in?

[soulbmx]

I just replaced the water pump on my Mercury outboard for the first time. When I reinstall the lower back in and it goes almost all the way in. But it still sticks out about 3/4's of an inch. I can put the bolts on, but it feels if I tighten them something will break.
I have the drive shaft in place properly (turned the flywheel to be sure) gear shaft in lined up and the water tube is in place.
The shifter is in neutral and so is the gear mechanism.

I'm stumped.

Am I missing something?

85HP. Mercury 115
1975
S/N: 4297426

 

[TD_Maker]

Re: Can't seem to get lower leg back in?

Did you lube the drive shaft spline before attempting to insert it? Also, when you changed the water pump. did you change the pump gromett too? Could the old one still be stuck on the tube?

 

[soulbmx]

Re: Can't seem to get lower leg back in?

I put a very thin layer of grease on the top of the drive shaft splines. And also wipped it off before installing it.
Do you mean the rubber seal on the top of the water pump that fits over the driveshaft, or something inside the pump?

 

[Chris1956]

Re: Can't seem to get lower leg back in?

Well, something is not fitting properly. Has the shift shafts mated? If you turn the flywheel you should see the driveshaft turn as well.

They are a tight fit, and need to be wiggled back into place. Make sure space is same at top and bottom of mating surfaces. Only tighten nuts with fingers until you get her totally mated, or you will ruin splines on the crank, driveshaft or shiftshaft. All expensive repairs..

 

[soulbmx]

Re: Can't seem to get lower leg back in?

There is a spring loaded pin at the top of the drive shaft that appears to be the issue. Should that be compressed as I tighten the bolts? The height of it is the same as the gap I have. And its the same amount of resistance when I push it in.

 

[soulbmx]

Re: Can't seem to get lower leg back in?

It's on now. Now to just get it to start.